A purpose built street car

[Jyrki]

Do you use a 'Kennebell' voltage booster for that Jyrki?

No, it's just a 12 VDC / 16VDC converter, supposed to live under rough conditions, 70A continuous, 120A momentary.
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Jyrki

[Martin]

I tried running without an alternator on mine, when i looked at the logs, the voltage used to drop to 9.8v at the top of the RPM scale, then on the drive back to the pits it would come back up to 11.9v

Martin

Hi,
The converter is supposed to keep voltage at over 15V as long as there is decent supply - the main battery can drop to 10V and the system still has 15V. Let's see if the converter lives up to the promise of the marketing material. I am logging also the supply voltage.
Jyrki

Nice, didnt know you could get one.....

[Jyrki]

Remains to be seen if it works in real life or not..
Jyrki

[58vw]

 

[Jyrki]

Report from the dyno two weeks ago:

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The plan for the first dyno session was to test the engine, transmission, electrics etc, and only run at modest load, then take it back to garage and check the motor and transmission oils, oil filter, valvetrain and leakdown before reaching for any real power, so we ran on 0.5bar wastegate springs only. We started with short sweeps at 15-30% throttle opening 1500-4000rpm, then moving up. The ‘small’ Garret GT4094R with a/r 1.19 exhaust made 0.5bar boost by 3500rpm with less than 40% TP, making it a nice street engine  The exhaust back pressure stayed at the same level as boost, but I wonder if the turbo will be good for 7000rpm and 1.5bar?

One of the reasons to go to dyno is to find new-car-issues, instead of finding them at the strip. First issue was a slipping clutch at little over 4000rpm, but during the following pulls the clutch started to hold, so it just needed to be seated in. Then there was an issue with the electric throttle going to fail safe on two pulls – it’s a duplicated signal and there was prob too big difference between them (more than 3% triggers the fail safe). It didn’t happen again but this needs to be figured out. Then while running up to 5500rpm, still running at less than 50% throttle opening, the fuel pressure dropped by 0.5-0.7 bar between 5100-5400rpm. We checked the electrics without finding anything, so figured it must be something mechanical. We didn’t have much time left, so just called it a day.

BTW, the 12V to 15.6V converter did its job all day.

By (unfair) comparison, the new engine made more torque with just 0.5bar boost and <50% throttle than the old 2332cc street engine did with full boost and full throttle (the one that ran 9.43 in a 900+ kg street car) on the same dyno 

Back in the garage I drained the oils and checked the oil filter. Engine oil was somewhat milky (running too rich with E85, oil temps below ethanol boiling point even though it was connected to the heater). Otherwise everything looked ok.

Then I took off the fuel filters (100 micron S/S pre-filter and 10 micron cellulose main filter) and disassembled them. The pre-filter had some soft stuff in the mesh (and I also found out that the design is restrictive), and the main filter looked ok. However, the stuff in the pre-filter resembles the cellulose material of the 10 micron filter? This is a very likely the reason for the drop in fuel pressure.

Next steps: new fuel filters, clean the injectors just to be sure and a new dyno session at some point. Still A LOT of little things to be done with the car...

Jyrki

[AntLockyer]

Nice work, I love the design of that dyno.

[MeXX]

Back in the garage I drained the oils and checked the oil filter. Engine oil was somewhat milky (running too rich with E85, oil temps below ethanol boiling point even though it was connected to the heater). Otherwise everything looked ok.

Jyrki

Dear Jyrki

As I also had a lot problems with alcohol in the oil  and tried different thinks on preheating, I wanted do ask U about your preheating set up.

1. Power of the heater?
2. where is it installed?
3. what temperature setpoint?
4. do you have circulation during preheating?
5. how much oil do you have?
6. how much drops the temperature when U start the cold engine ?

MeXX

[tikimadness]

Very impressive stuff Jyrki . I would be over the moon if my car ends up half the quality yours is.

Michael

[Jyrki]

Back in the garage I drained the oils and checked the oil filter. Engine oil was somewhat milky (running too rich with E85, oil temps below ethanol boiling point even though it was connected to the heater). Otherwise everything looked ok.

Jyrki

Dear Jyrki

As I also had a lot problems with alcohol in the oil  and tried different thinks on preheating, I wanted do ask U about your preheating set up.

1. Power of the heater?
2. where is it installed?
3. what temperature setpoint?
4. do you have circulation during preheating?
5. how much oil do you have?
6. how much drops the temperature when U start the cold engine ?

MeXX

1.   300W. It is enough to heat the oil in the oil tank in a decent time, but….
2.   oil-tank, which holds 50% of all oil
3.   none. There is a timer in the electric supply, or alternatively it is ON all the time
4.   nothing automatic. I sometimes circulate w/ starter engine
5.   about 9 litres
6.   if I heat 50% of oil to 70-80C in 20C garage and start the engine, the oil temp drops below 50C once the heads have reached 70-80C

Maybe I should add another heater element in the engine case oil sump (there is prob 2 liters of oil ??)??

Jyrki

[Martin]

looking fantasic,

Nice to know the voltage converter is working.

[Shag55]

Nice!

[Jyrki]

Whoohoo, the new wheels arrived some time ago, and with the help of Tomi, Sami and Make we got the windows installed and lifted the body over the chassis.
The wheels are 8½x15 and 3½x15 Fuchs replicas (5 x 4 3/4" bolt pattern, custom et, custom lug nut setup) from Image Wheels (http://www.imagewheels.co.uk/index.html). I am really happy with their product and service! 5 weeks from initial query to delivery 

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Jyrki

[Andy Sykes]

Loving those wheels and made about 2 hours fom me very nice, and your car is dam cool too

[vwcab]

It's getting BETTER and BETTER,love it!!!!!
 

[SPRasmussen]

That is badass, one of the coolest builds on this forum 

[Trond Dahl]

That is badass, one of the coolest builds on this forum 

That came from the guy with the other one :-)
But yes, I totally agree:-)

[Fredy Kucmocht]

Are this the original steel fenders and the tyres are 10,5 x 28 ?
Please,do you have pics from the inside of the fenders.
Great car,thanks Fredy

[Jonny Grigg]

Hi Jyrki,

I love this thread- one of the most awesome VW builds I have seen in a very long time. Great engineering and attention to detail.

Just as an aside, now that you have changed your wheels, if you ever think about selling on those Billet Specialties Street Lites, I' d be very interested in buying them off you. Just a thought.

Cheers,

Jonny.

[Neil Davies]

Loving those wheels and made about 2 hours fom me very nice, and your car is dam cool too

Just 25 minutes from me!

Car looks amazing Jyrki, subtle but insane at the same time. Brilliant.

[Jyrki]

Are this the original steel fenders and the tyres are 10,5 x 28 ?
Please,do you have pics from the inside of the fenders.
Great car,thanks Fredy

Hi,
Yes, the fenders are original steel fenders. They are std width, or maybe even slightly narrower towards the rear of the fender. The tires are M/T 9x28x15, which in reality are about 27.3" tall. 5" narrowed, Geers brakes, 8.5" wheels with 3.75" BS. With this setup ideal back-spacing would be around 3.25-3.5".
I'll take some pictures under the fenders.
Jyrki

[Fredy Kucmocht]

Thank you so much Jyrki !

[Jyrki]

Here are some poor quality pics of the rear fender tabs. The tabs are raised so that the Dzus' springs are not the first to touch the tires, just in case the car squats too much.

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Then a picture of the stance (the front runners are not yet on the 3½" Fuchs replicas) :

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And one more; almost everything fits under the panels. I had to take off the right side fuel rail; but it's an easy modification to make it fit.

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Jyrki

[Airspeed]

Fecking awesome!

Good thinking on the raised tabs too!

[fahrvergnugen]

Bad ass car, love it.

[Andy Sykes]

Absolutely awesome 

[Fredy Kucmocht]

wow, to faint !
Please one pic from the inside of the fender
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[Jesus]

Such an Awesome Project, Looks Amasing!

[58vw]

awesome pics...keep em coming

[valtteri]

Wow. Just wow. I think this time Jyrki has really hit the gold vein for style. I have to say it's one of the coolest-looking VW rides I've seen in a very long time, if not ever. WAIT...what...it goes fast too? Even more amazing.

The motivation for our hobby is built on cornerstone cars like this: they come few and far between but this is one of them.

[Ragtop]

I totally agree with previous speaker.